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FP5

REMOWELD Résumé de rapport

Project ID: G1RD-CT-2000-00332
Financé au titre de: FP5-GROWTH
Pays: Greece

Know-How for modelling and simulating remote welding

The RemoWeld project aimed to an extended, sustainable and competitive use of remote laser welding systems promoting the development of competitive manufacturing procedures.

In this project the main task of UPATRAS was the development of remote laser welding process simulation models. The main results that have been achieved through the Project’s lifetime include:
- Literature research on previous analytical conventional laser welding simulation models.

- Modification of existing laser welding simulation models as to integrate the remote approach.

- Geometrical analysis and modelling of the CO2 and Nd:YAG remote welding scanning systems in order to evaluate the beam profiles for different incidence angles inside the working volume.

- Realization of experiments with the CO2 RWS on three different welding combinations (automotive and non-automotive).

- Realization of experiments with the Nd:YAG RWS on two different welding combinations (non-automotive). The investigated process parameters included the laser power, the welding speed, the incidence angle, the air knife direction and the air pressure. The measured characteristics include the weld depth and width, the weld angle and the undercut for the Volvo material.

- Application of statistical modelling using the method of statistical design of experiments.

- Application of empirical modelling of the weld characteristics using the results from the experimental work.

These results contain process models that provide quality characteristics of the welds as functions of the process parameters for different weld combinations and materials required by the end users.

UPATRAS aims to disseminate the obtained results to the scientific and academic community through at least two publications – presentations in conferences and workshops. A PhD thesis and two student theses projects will be completed 12 months after the completion of the project. The achieved results can be directly implemented by off-line programming software codes developed for laser processing (remote or not).

The potential end users that could respond to the results obtained on Remote Welding process modelling involve software developers for programming and controls, developers of process monitoring systems and direct remote laser welding and conventional laser welding users (automotive and non-automotive) for optimisation and controlling of the process.

The main innovation featured by the referred results is related to the remote (inclined) approach of the laser beam to the workpiece, which distorts the laser power density and affects significantly the quality characteristics of the resulting welds. Such phenomenon and others as well that derive from the remote (inclined) approach haven’t been investigated so far in theoretical or/and experimental level.

Contact

George CHRYSSOLOURIS, (Director of the Laboratory for Manufacturing Systems)
Tél.: +30-2610997262
Fax: +30-2610997744
E-mail